Esters of certain oxyalkylated phenol-aldehyde resins with polyhydric alcohol-polybasic carboxy acid acyloxy acid esters



Patented Jan. 8, 1952 omen ESTERS OF CERTAIN OXYALKYLATED PHENOL-ALDEHY DE RE SIN S WITH POLYHYDRIC ALCOHOL POLYBASIC CARBOXY ACID A ESTERS CYLOXY ACID Melvin De Groote, St. Louis, and Bernhard Keiser, Webster Groves, Mo., assignors to Petrolite Corporation, Ltd., Wilmington, Del., a corporation of Delaware No Drawing. Application December 10, 1948, Serial No. 64,465

7 Claims. (Cl. 260- 20) The present invention is concerned with certain new chemical products, compounds, or compositions, having useful application in various arts. This invention is a continuation-in-part of our co-pending application, Serial No. 726,217, filed February 3, 1947 and now abandoned. It includes methods or procedures for manufacturing said new products, compounds or compositions, as well as the products, compounds or compositions themselves.

Said new compounds are the resultant of the esterification reaction involving, on the one hand, (a) a polyhydric alcohol radical, (b) a polybasio carboxylic acid radical, and (c) an acyloxy radical containing 8 to 32 carbon atoms derived from a detergent-forming monocarboxy acid having 8 to 32 carbon atoms, atleast one polyhydric alcohol radical being ester-linked with a group containing said acyloxy radical and the number of said groups ester-linked with at least one polyhydric alcohol radical being less than the valency of said polyhydric alcohol radical; and on the other hand, is that of certain hydrophile synthetic products; said hydrophile synthetic products being oxyalkylation products of (A) an alpha-beta alkylene oxide having not more than 4 carbon atoms and selected from the class consisting of ethylene oxide, propylene oxide, butylene oxide, glycide and methylglycide, and (B) an oxyalkylation-susceptible, fusible, organic solvent-soluble, Water-insoluble phenol-aldehyde resin; said resin being derived by reaction between a difunctional monohydric phenol and an aldehyde having not over 8 carbon atoms and reactive toward said phenol; said resin being formed in the substantial absence of trifunctional phenols; said phenol being of the formula in which R is a hydrocarbon radical having at least 4 and not more than 12 carbon atoms and substituted in the 2,4,6 position; said oxyalkylated resin being characterized by the introduction into the resin molecule of a plurality of divalent radicals having the formula (R) n, in which R1 is a member selected form the class consisting of ethylene radicals, propylene radicals, butylene radicals, hydroxypropylene radicals, and

hydroxybutylene radicals, and n is a numeral varying from 1 to 20; with the proviso that at least 2 moles of alkylene oxide be introduced for each phenolic nucleus.

Although the herein described products have a number of industrial applications, they are of particular value for resolving petroleum emulsions of the water-in-oil type that are commonly referred to as cut oil, roily oil, emulsified oil, etc., and which comprise fine droplets of naturally-occurring waters or brines dispersed in a more or less permanent state throughout the oil which constitutes the continuous phase of the emulsion. This specific application is described and claimed in our co-pending application, Serial No. 64,464, filed December 10, 1948 now Patent No. 2,541,999 issued February 20, 1951. See also our co-pending application, Serial No. 64,469, filed December 10, 1948.

The new products are useful as wetting, detergent and levelling agents in the laundry, textile and dyeing industries; as wetting agents and detergents in the acid washing of building stone and brick; as wetting agents and spreaders in the application of asphalt in road building and the 'likeyas a flotation reagent in the flotation separation of various aqueous suspensions containing negatively charged particles such as;

sewage, coal washing waste water, and various trade. wastes and the like; as germicides, insecticides, emulsifying agents, as for example, for

cosmetics, spray oils, water-repellent textile finishes; as lubricants, etc. I For purpose of convenience what is said hereinafter' will be divided into three parts. Part 1 will be'concerned' with the production of the resin from a difunctional phenol and an aldehyde; Part 2- will be concerned with the oxyalkyla t'ion of the resin so as to convert it into a hydrophile hydroxylated derivative; Part 3 will be concerned with the preparation of the acidic reactant which is subsequently combined with the hydroxylated products described in Part 2 immediately preceding;

PART 1 As to the preparation of the phenol-aldehyded l 1 1 such qq-p n i i p at ns we dei scribed a fusible, organic solvent-soluble, waterinsoluble resin polymer of the formula In such idealized representation n is a numeral varying from 1 to 13 or even more, provided that the resin is fusible and organic solvent-soluble. R is a hydrocarbon radical having at least 4 and not over 8 carbon atoms. In the instant application R may have as many as 12 carbon atoms, as in the case of a resin obtained from a dodecylphenol. In the instant invention it may be first suitable to describe the alkylene oxides employed as reactants, then the aldehydes, and finally the phenols, for the reason that the latter require a more elaborate description. v

The alkylene oxides which may be used are the alpha-beta oxides having not more than 4 carbon atoms, to wit, the alpha-beta ethylene oxide, alpha-beta propylene oxide, alpha-beta butylene oxide, glycide, and methylglycide.

Any aldehyde capable of forming a methylol or a substituted methylol group and having not more than 8 carbon atoms is satisfactory, so long as it does not possess some other functional group or structure which will conflict with the resinification reaction or with the subsequent oxyalkylation of the resin, but the use of formaldehyde, in its cheapest form of an aqueous solution, for the production of theresins is particularly advantageous. Solid polymers of formaldehyde are more expensive and higher aldehydes are both less reactive, and are more expensive. Furthermore, the higher aldehydes may undergo other reactions which are not desirable, thus introducing difficulties into the resinification step. Thus acetaldehyde, for example, may undergo an aldol condensation, and it and most of the higher aldehydes enter into self-resinification when treated with strong acids or alkalies. On the other hand, higher aldehydes frequently beneficially affect the solubility and fusibility of a resin. This is illustrated, for example, by the different characteristics of the resin prepared from para-tertiary amylphenol and formaldehyde on one hand, and a comparable product prepared from the same phenolic reactant and heptaldehyde on the other hand. The former, as shown in certain subsequent examples, is a hard, brittle, solid, whereas the latter is soft and tacky, and obviously easier to handle in the subsequent oxyalkylation procedure.

Cyclic aldehydes may be employed, particularly benzaldehyde. The employment of furfural requires careful control for the reason that in addition to its aldehydic function, furfural can form condensations by virtue of its unsaturated structure. The production of resins from furfural for use in preparing products from the present process is most conveniently conducted with weak alkaline catalysts and often with alkali metal carbonates. Useful aldehydes, in addition to formaldehyde, are acetaldehyde, propionic aldehyde, butyraldehyde, 2-e thylhexanal, ethyl-'- butylraldehyde, hepta'ldehyde, and benzaldehyde, furfural and glyoxal. It would appear that the use of glyoxal should be avoided due to the fact that it is tetrafunctional. However, our experience has been that, in resin manufacture and particularly as described herein, apparently only one of the aldehydic functions enters into the resinification reaction. The inability of the other aldehydic function to enter into the reaction is presumably due to steric hindrance. Needless to say, one can use a mixture of two or more aldehydes although usually this has no advantage.

Resins of the kind which are used as intermediates in this invention are obtained with the use of acid catalysts or alkaline catalysts, or without the use of any catalyst at all. Among the useful alkaline catalysts are ammonia, amines, and quaternary ammonium bases. It is generally accepted that when ammonia and amines are employed as catalysts they enter into the condensation reaction and, in fact, may operate by initial combination with the aldehydic reactant. The compound hexamethylenetetramine illustrates such a combination. In light of these various reactions it becomes diiiicult to present any formula which would depict the structure of the various resins prior to oxyalkylation, More will be said subsequently as to the difference between the use of an alkaline catalyst and an acid catalyst; even in the use of an alkaline catalyst there is considerable evidence to indicate that the products are not identical where different basic materials are employed. The basic materials employed include not only those previously enumerated but also the hydroxides of the alkali metals, hydroxides of the alkaline earth metals, salts of strong bases and weak acids such as sodium acetate, etc.

Suitable phenolic reactants include the following: Paratertiarybutylphenol; para-secondarybutylphenol; para-tertiary-amylphenol; parasecondary-amylphenol; para-tertiary-hexylphenol; para-isooctylphenol; ortho-phenylphenol; para-phenylphenol; ortho-benzylphenol; parabenzylphenol; and para-cyclohexylphenol, and the corresponding ortho-para substituted metacresols and 3,5-xylenols. Similarly, one may use paraor ortho-nonylphenol or a mixture, paraor decylphenol or a mixture, methylphenol, or paraor ortho-dodecylphenol.

The phenols herein contemplated for reaction may be indicated by the following formula:

in which R is selected from the class consisting of hydrogen atoms and hydrocarbon radicals having at least 4 carbon atoms and not more than 12 carbon atoms, with the proviso that one occurrence of R is the hydrocarbon substituent and the other two occurrences are hydrogen atoms, and with the further provision that one or both of the 3 and 5 positions may be methyl substituted.

The above formula possibly can be restated more conveniently in the following manner, to wit, that the phenol employed is of the following formula, with the proviso that R is a hydrocarbon substituent located in the 2,4,6 position, again with the provision as to 3 or 3,5 methyl substitution. This is conventional nomenclature, numbering the various positions in the usual clockwise manner, beginning with the hydroxyl position as one:

The manufacture of thermoplastic phenolaldehyde resins, particularly from formaldehyde and a difunctional phenol, i. e., a phenol in which one of the three reactive positions (2,4,6) has been substituted by a hydrocarbon group, and particularly by one having at least 4 carbon atoms and not more than 12 carbon atoms, is well known. As has been previously pointed out, there is no objection to a methyl radical provided it is present in the 3 or 5 position.

These resins, used as intermediates to produce the products of the present invention are described in detail in our Patent 2,499,370, granted March 7, 1950, and specified examples of suitable resins are those of Examples 1a through 103a of that patent,and reference is madethereto for a description of these intermediate resins and for examples thereof.

PART 2 Having obtained a suitable resin of the kind described, such resin is subjected to treatment with a low molal reactive alpha-beta olefin oxide so as to render the product distinctly hydrophile in nature as indicated by the fact that it becomes self-emulsifiable or miscible or soluble in water, or self-dispersible, or has emulsifying properties. The olefin oxides employed are characterized by the fact that they contain not over 4 carbon atoms and are selected from the class consisting of ethylene oxide, propylene oxide, butylene oxide, glycide, and methylglycide. Glycide may be, of course, considered as a hydroxy propylene oxide and methyl glycide as a hydroxy butylene oxide. In any event, however, all such reactants contain the reactive ethylene oxide ring and may be best considered as derivatives of or substituted ethylene oxides. The solubilizing effect of the oxide is directly proportional to the percentage of oxygen present, or specifically, to the oxygen-carbon ratio.

In ethylene oxide, the oxygen-carbon ratio is 1:2. In glycide, it is 2:3; and in methyl glycide, 1:2. In such compounds, the ratio is very favorable to the production of hydrophile or surfaceactive properties. However, the ratio, in propylene oxide, is 1:3, and in butylene oxide, 1:4. Obviously, such latter two reactants are satisfactorily employed only where the resin composition is such as to make incorporation of the desired property practical. In other cases, they may produce marginally satisfactory derivatives, or even unsatisfactory derivatives. They are usable in conjunction with the three more favorable alkylene oxides in all cases. For instance, after one or several propylene oxide or butylene oxide molecules have been attached to the resin molecule, oxyalkylation may be satisfactorily continued using the more favorable members of the class, to produce the desired hydrophile product. Used alone, these two reagents may in some cases fail to produce sufficiently hydrophile derivatives because of their relatively low oxygen-carbon ratios.

Thus, ethylene oxide is much more effective than propylene oxide, and propylene oxide is more effective than butylene oxide. Hydroxy propyl-' ene oxide (glycide) is more effective than propylene oxide. Similarly, hydroxy butylene oxide (methyl glycide) is more eiTective than butylene oxide, Since ethylene oxide is the cheapest alkylene oxide available and is reactive, its use is definitely advantageous, and especially in light of its high oxygen content. Propylene oxide is less reactive than ethylene oxide, and butylene oxide is definitely less reactive than propylene oxide. On the other hand, glycide may react with almost explosive violence and must be handled with extreme care.

The oxyalkylation of resins of the kind from which the initial reactants used in the practice of the present invention are prepared is advantageously catalyzed by the presence of an alkali. Useful alkaline catalysts include soaps, sodium acetate, sodium hydroxide, sodium methylate, caustic potash, etc. The amount of alkaline catalyst usually is between 0.2% to 2 vThe temperature employed may vary from room temperature to as high as 200 C. The reaction may be conducted with or without pressure, 1. e., from zero pressure to approximately 200 or even 300 pounds gauge pressure (pounds per square inch). In a general way, the method employed is substantially the same procedure as used for oxyalkylation of other organic materials having reactive phenolic groups.

It may be necessary to allow for the acidity of a resin in determining the amount of alkaline catalyst to be added in oxyalkylation. For instance, if a nonvolatile strong acid such as sulfuric acid is used to catalyze the resinificati'on reaction, presumably after being converted into a sulfonic acid, it may be necessary and is usually advantageous to add an amount of alkali equal stoichiometrically to such acidity, and include added alkali over and above this amount as the alkaline catalyst.

It is advantageous to conduct the oxyethylation in presence of an inert solvent such, as xylene, cymene, decalin, ethylene glycol diethylether, diethyleneglycol diethylether, or the like, although with many resins, the oxyalkylation proceeds satisfactorily without a solvent. Since xylene is cheapand may be permitted to be present in the final product used as a demulsifier, it is our preference to use xylene. This is particularly true in the manufacture of products from low-stage resins, i. e., of 3 and up to and including 7 units per molecule.

If a xylene solution is used in an autoclave as hereinafter indicated, the pressure readings of course represent total pressure, that is, the combined pressure due to xylene and also due to ethylene oxide or whatever other oxyalkylating agent is used. Under such circumstances it may be necessary at times to use substantial pressures to obtain effective results, for instance, pressures up to 300 pounds along with correspondingly high temperatures, if required.

However, even in the instance of high-melting resins, a solvent such as xylene can be eliminated in either one of two ways: After the introduction of approximately 2 or 3 moles of ethylene oxide, for example, per phenolic nucleus, there is a definite drop in the hardness and melting point of the resin. At this stage, if xylene or asimilar solvent has been added, it can be eliminated by distillation (vacuum distillation if desired) and the subsequent intermediate, being comparatively soft and solvent-free, can be reacted further in the usual manner with ethylene oxide or some other suitable reactant.

Another procedure is to continue the reaction to completion with such solvent present and then eliminate the solvent by distillation in the customary manner.

Another suitable procedure is to use propylene oxide or butylene oxide as a solvent as well as a reactant in the earlier stages along with ethylene oxide, for instance, by dissolving the powdered resin in propylene oxide even though oxyalkylation is taking place to a greater or lesser degree. After a solution has been obtained which represents the original resin dissolved in propylene oxide or butylene oxide, or a mixture which includes the oxyalkylated product, ethylene oxide is added to react with the liquid mass until hydrophile properties are obtained. Since ethylene oxide is more reactive than propylene oxide or butylene oxide, the final product may contain some unreacted propylene oxide or butylene oxide which can be eliminated by volatilization or distillation in any suitable manner.

, Attention is directed to the fact that the resins herein described must be fusible or soluble in an organic solvent. Fusible resins invariably are soluble in one or more organic solvents such as those mentioned elsewhere herein. It is to be emphasized, however, that the organic solvent employed to indicate or assure that the resin meets this requirement need not be the one used in oxyallrylation. Indeed, solvents which are susceptible to oxyalkylation are included in this group of organic solvents. Examples of such solvents are alcohols and alcohol-others. However, where a resin is soluble in an organic solvent, there are usually available other organic solvents which are not susceptible to oxyallrylation, useful for the oxyalkylation step. In any event, the organic solvent-soluble resin can be finely powdered, for instance to 100 to 200 mesh, and a slurry or suspension prepared in. xylene or the like, and subjected to oxyalxylation. The fact that the resin is soluble in an organic solvent or the fact that it is fusible means that it consists of separate molecules. Phenol-aldehyde resins of the type herein specified possess reactive hydroxyl groups and are oxyalkylation susceptible.

Considerable of what is said immediately hereinafter is concerned with ability to vary the hydrophile properties of the hydroxylated intermediate reactants from minimum hydrophile properties to maximum hydrophile properties. Such properties in turn, of course, are effected subsequently by the acid employed for esterification and the quantitative nature of the esterification itself, i. e., whether it is total or partial. It may be well, however, to point out what has been said elsewhere in regard to the hydroxylated intermediate reactants. See, for example, our co-pending applications, Serial Nos. 8,730 and 8,731, both filed February 16, 1948, and Serial No. 42,133, filed August 2, 1948, and Serial No. 42,134, filed August 2, 19% all four of which are now abandoned. The reason is that the esterification, depending on the acid selected, may vary the hydrophile-hydrophobe balance in one direction or the other, and also invariably causes the development of some property which makes it inherently dififerent from the two reactants from which the derivative ester is obtained.

Referring to the hydrophile hydroxylated intermediates, even more remarkable and equally difficult to explain, are the versatility and the utility of these compounds considered as chemical reactants as one goes from minimum hydrophile property to ultimate maximum hydrophile property. For instance, minimum hydrophile property may be described roughly as the point where two ethyleneoxy radicals or moderately in excess thereof are introduced per phenolic hydroxyl. Such' minimum hydrophile property or subsurface-activity or minimum surface-activitymeans that the product shows at least emulsify ing properties or self-dispersion in cold or even in warm distilled water (15 to 40 C.) in concentrations of 0.5% to 5.0%.

water, and may even be very insoluble in boiling water. Moderately high temperatures aid in reducing the viscosity of the solute under examination. Sometimes if one continues to shake a hot solution, even though cloudy or containing an insoluble phase, one finds that solution takes place to give a homogeneous phase as the mixturecools.

Such self-dispersion tests are conducted in the.

absence of an insoluble solvent.

When the hydrophile-hydrophobe balance is above the indicated minimum (2 mole of ethylene oxide per phenolic nucleus or the equivalent) but insufilcient to give a sol as described immediately preceding, then, and in that event hydrophile properties are indicated by the fact that one can produce an emulsion by having present 10% to 50% of an inert solvent such as xylene. All that one need to do is to have a xylene solution within the range of 50 to part by weight. of oxyalkylated derivatives and 50 to 10 partsby weight of xylene and mix such solution with one, two or three times its volume of distilled water and shake vigorously so as to obtain an emulsion which may be of the oil-in-water type or the Water-in-oil type (usually the former) but, in any event, is due to the hydrophile-hydrophobe balance of the oxyalkylated derivative. We prefer simply to use the xylene diluted derivatives, which are described elsewhere, for this test rather than evaporate the solvent and employ any more elabcrate tests, if the solubility is not sufiicient to permit the simple sol test in water previously noted.

If the product is not readily water soluble it may be dissolved in ethyl or methyl alcohol, ethylene glycol diethylether, or diethylene glycol diethylether, with a little acetone added if required, making a rather concentrated solution, for instance 40% to 50%, and then adding enough of the concentrated alcoholic or equivalent solution to give the previously suggested 0.5% to 5.0 strength solution. If the product is self-dispersing (1. e., if the oxyalkylated product is a liquid or a liquid solution self-emulsifiable), such sol or dispersion is referred to as at least semi-stable in the sense that sols, emulsions, or dispersions prepared are relatively stable, if they remain at least for some period of time, for instance 30 minutes to two hours, before showing any marked separation. Such tests are conducted at room temperature (22 C.). Needless to say, a. test can be made in presence of an insoluble solvent such as 5% to 15% of xylene, as noted in previous examples. If such mixture, i. e., containing a Water-insoluble solvent, is at least semi-stable, obviously the solvent-free product would be even more so. Surface-activity representing an advanced hydrophile-hydrophobe balance can also be determined by the use of conventional measurements hereinafter described. One outstanding characteristic property indicating surface activity in a material is the ability to form a per-. manent foam in dilute aqueous solution, for ex-.

ample, less than 0.5%, when in the higher oxyalkylated stage, and to form an emulsion in the lower and intermediate stages of oxyalkylation.

Allowance must be made for the presence of a solvent in the final product in relation to the hydrophile properties of the final product. The

76 principle involved in the manufacture of the These materials, are. generally more soluble in cold water than warm.

herein contemplated compounds for use as pol hydric reactants is based on the conversion of a hydrophobe or non-hydrophile compound or mixture of compounds into products which are dis- .tinctly hydrophile, at least to the extent that they have emulsifying properties or are selfemulsifying; that is, when shaken with water they produce stable or semi-stable suspensions, or, in the presence of a water-insoluble solvent, such as xylene, an emulsion. In demulsification, it is sometimes preferable to use a product having markedly enhanced hydrophile properties over and above the initial stage of self-emulsifiability, although we have found that with products of the type used herein, most eflicacious result are obtained with products which do not have hydrophile properties beyond the stage of self-dispersibility.

More highly oxyalkylated resins give colloidal solution or sols which show typical properties comparable to ordinary surface-active agents. Such conventional surface-activity may be measured by determining the surface tension and the interfacial tension against parafiin oil or the like. At the initial and lower stages of oxyalkylation, surface-activity is not suitably determined in this same manner but one may employ an emulsification test. Emulsions come into existence as a rule through the presence of a surface-active emulsifying agent. Some surface-active emulsifying agents such as mahogany soap may produce a water-in-oil emulsion or an oil-in-water emulsion depending upon the ratio of the two'phases, degree of agitation, concentration of emulsifying agent, etc.

The same is true in regard to the oxyalkylated resins herein specified, particularly in the lower stage of oxyalkylation, the so-called sub-surface-active stage. The surface-active properties are readily demonstrated by producing a xylenewater emulsion. A suitable procedure is as follows: The oxyalkylated resin is dissolved in an equal weight of xylene. Such 50-50 solution is then mixed with 1-3 volumes of water and shaken to produce an emulsion. The amount of xylene is invariably suiiicient to reduce even a tacky resinous product to a solution which is readily dispersible. The emulsions so produced are usually xylene-in-water emulsions (oil-in-water type) particularly when the amount of distilled water used is at least slightly in excess of the volume of xylene solution and also if shaken Vigorously. At times, particularly in the lowest stage of oxyalkylation, one may obtain a waterinxylene emulsion (water-in-oil type) which is apt to reverse on more vigorous shaking and further dilution with water.

If in doubt as to this property, comparison with a resin obtained from para-tertiary butylphenol and formaldehyde (ratio 1 part phenol to 1.1

formaldehyde) using an acid catalyst and then followed by oxyalkylation using 2 moles of ethylene oxide for each phenolic hydroxyl, is helpful. Such resin prior to. oxyalkylation has a molecular weight indicating about 4 units per resin molecule. Such resin, when diluted with an equal weight of xylene, will serve to illustrate the above emulsification test.

In a few instances, the resin may not be sufficiently soluble in xylene alone but may require the addition of some ethylene glycol diethylether as described elsewhere. It is understood that such mixture, or any other similar mixture, is considered the equivalent of xylene for the purpose of this test.

In many cases, there is no doubt as to the presence or absence of hydrophile or surfaceactive characteristics in the polyhydric reactants used in accordance with this invention. They dissolve or disperse in water; and suchdispersions foam readily. With borderline cases, i. e., those which show only incipient hydrophile or surface-active property (sub-surfaceeactivity) tests for emulsifying properties or self-dispersibility are useful. The fact that a reagent is capable of producing a dispersion in water is proof that it is distinctly hydrophile. In doubtful cases,

comparison can be made with the b'utylphenolformaldehyde resin analog wherein 2 moles of ethylene oxide have been introduced for each phenolic nucleus.

The presence of xylene or an equivalent water'- insoluble solvent may mask thepoint at which a solvent-free product on m'ere dilution in a-atest tube exhibits self-emulsification. For this reason, if it is desirable to determine the approximate point where self-emulsification begins, then it is better to eliminate the xylene or equivalent from a small portion of the reaction mixture and test such portion. In some cases,such xy lene-free resultant may show initial or incipient hydrophile properties, whereas in presence of xylene such properties would not be'noted. In other cases, the first objective indication of hydrophile properties may be the capacity of the material to emulsify an insoluble solvent such as xylene. It is to beemphasized that hydrophile propertiesherein referred to are such as those exhibited by incipientself-emulsification orthe presence of emulsifying properties and go through the range of homogeneous dispersibility or admixture with'water even in presence 'of added water-insoluble solvent and minor proportions of common eletrolytes as occur in oil field brines. i

Elsewhere,'it is pointed out thatan emulsification test may be used to determine ranges of surface-activity and that such emulsification tests'employ a xylene solution. Stated another way, it is really immaterial whether a xylene solution produces a sol or'whether it merely produces anemulsion.

In light of what has been said previously in regardto the variation of range of hydrophile properties, and also in light of what has been said as tothe variation in the-"effectiveness of various alkylene oxides, and most particularly of all ethylene oxide, to introduce hydrophile character, it becomes obvious that there is a wide variation in the amount of al-kylene oxide-employedyas long as it is atleast 2 moles per phenolic nucleous, for producing products useful for the practice of this invention. Another variation is the molecular size of the'resin' chain resulting'from reaction between the difunctional phenol and the aldehyde such as formaldehyde. It is well known that the size and nature or structure of the resin polymer obtained'varies somewhat with the conditions of reaction, the proportions ofreactants, the nature of the catalyst, etc.

Based on molecular weight determinations, most of the resins prepared as herein described, particularly in'the absence of a secondary heating step, contain 3 to 6 or '7 phenolic nuclei with approximately 4 or 5 nuclei as an average. More drastic conditions of resinification yield resins of greater chain length. Such more intensive resinification-is a conventional procedure and may be yemployed if desired. Molecular weight, of course, is -measured by any suitable .used in preparing the resin. A combination of castalysts is sometimes used in two stages; for instance, analkaline catalyst is sometimes employed .in aiirststage, followed by neutralization and adidtion of a small amount of acid catalyst in a second stage. It-is generally believed that even .in the presence :of an alkaline catalyst, the number "of :moles of aldehyde, such as'formaldehyde, must be 'greaterthanthe moles of phenol employed in order t introduce'methylol groups in the intermediatestage. Therels no indication that: such groups appear in the: final resin if preparedby theme of :an acid catalyst. It is possible thatsuchgroups may appear in the finished resins prepared solely with an alkaline catalyst; but'weihave never :beenable to confirm this fact in an examination of a large number of resins preparedby ourselves. Our preference, however, is to .use an acid-catalyzed resin, particularly employing a .i'ormaldehyd'e-itoephenol ratio of 0.95 to 1.20. and, as "faras we have been able to determine, such resins are free from methylol groups. Asaa matter offact, it is probable that in acid-catalyzed resinifications, the methylol structure may appear only momentarily at the very "beginning of the reaction and in all probability is converted at once into a more complex structure during the intermediate stage.

One procedure which can be employed in the use of arrow resin to prepare polyhydric reactants for use in the preparation of compounds employed in the present invention, is to determine the hydroxyl value by the Verley-Bdlsing method or its equivalent. The resin as such, or in the "form of a "solution-as described,'is-then treated with ethylene oxide in presence of 0.5% to 2% ofsodiummethylate'as a catalyst in stepwise fashion. The conditions of reaction, as far-as time or percent are concerned, are within the range previously indicated. With suitable agitation the ethylene oxide, if added in molecu lar proportion, combines within a-comparatively short time, for instance afew minutes to 2 to 6 hours, but in some instances requires as much as 8 to '24 hours. A useful temperature range is from 125 to 225 C. The-completion of the reaction of each addition of ethylene oxide in step-wise fashion is-usually indicated by the reduction or elimination of pressure. An amount conveniently'used foreach addition is generally equivalent to a, mole or two moles of ethylene oxide per hydroxyl radical. When the amount of ethylene oxide added is equivalent'to approximately 50% by weight of "the original resin, a sample is tested for incipient hydrophile properties by simply shaking up in water as'is, or after the elimination of the solvent if a solvent is present. The amount of ethylene oxide used'to obtain a useful defulsifying agent as a rule varies from 70% by weight of the original resin to as much as five or six times the weight of the original resin. In the case-of a resin derived from para-tertiary butylphenol, as little as 50% by weight of ethylene oxide may give suitable solubility. With propylene oxide, even a greater molecular proportion is required and sometimes which no hydroxyl is present.

Attention is directed to the fact that in the subsequent examples reference is made to the stepwise addition of the alkylene oxide, such as ethylene oxide. It is understood, of course, there is no objection to the continuous addition of:al kylene oxide until the desired stage ofrreaction is reached. In fact, there may be less of a hazard involved and it is often advantageous to add the alkylene oxide slowly in a continuous stream and in such amount as to avoid exceeding the higher pressures noted in the various examples or elsewhere.

It may be well to emphasize the fact that when resins are produced from diiunctional phenols and some of the higher aliphatic aldehydes, such as .acetaldehyde, the resultant is a comparatively soft or pitch-like resin at ordinary temperatures. Such resins become comparatively fluid at 110 to 165 C. as a rule, and thus can be readily oxyalkylated, preferably oxyethylated, without the use of a solvent.

What has been said previously is not intended to suggest that any experimentation is necessary to determine the degree of oxyalkylation, and particularly oxyethylation. What has been said previously is submitted primarily to emphasize the fact that these remarkable oxyalkylated resins having surface activity show unusual properties as the hydrophile character varies from a minimum to an ultimate maximum. One should not underestimate the utility of any of these polyhydric alcohols in a surface-active or sub-surface-active range Without examining them by reaction with a number of the typical esters herein described and subsequently examining the resultant for utility, either in demulsification or in some other art or industry as referred to elsewhere, or as a reactant for the manufacture of more complicated derivatives.

A few simple laboratory tests which can be conducted in a routine manner will usually give all the information that is required.

For instance, a simple rule to follow is to prepare a resin having at least three phenolic nuclei and being organic solvent-soluble. Oxyethylate such resin, using the following {our ratios of moles of ethylene oxide per phenolic unit equivavalent: 2 to l; 6 to 1; 16 to l; and 15 to 1. From a sample of each product remove any solvent that may be present, such as xylene. Prepare 0.5% and 5.0 solutions in distilled water, as previously indicated. A mere examination of such series will generally reveal an approximate range of minimum hydrophile character, moderate hydrophile character, and maximum hydrophile character. If the 2 to 1 ratio does not show minimum hydrophile character by test of the solvent-free product, then one should test its capacity to form an emulsion when admixed with xylene or other insoluble solvent. If neither test shows the required minimum hydrophile property, repetition using 2 /2 to l moles per phenolic nucleus will serve. Moderate hydrophile character should be shown by either the 6 to 1 or 10 to 1 ratio. Such moderate hydrophile character is indicated by the fact that the sol in distilled Water within the previously men- .hydrophobe range.

' tioned concentration range is a permanent translucent sol when viewed in a comparatively thin layer, for instance the depth of a test tube. Ultimate hydrophile character is usually shown at the 15 to 1 ratio test in that adding a small quire the use of increased amounts of alkylene oxide. However, if one does not even care to go to the trouble of calculating molecular weights, one can simply arbitrarily prepare compounds containing ethylene oxide equivalent to about 50% to 75% by weight, for xample 65% by weight, of the resin to he oxyethylated; a second example using approximately 280% to 300% by weight, and a third example using about 590% to 700% by weight, to explore the range of hydrophile-hydrcphobe balance.

A practical examination of the factor of oxyalkylation level can be made by a very simple test using a pilot plant autoclave having a capacity of about to gallons as hereinafter described. Such laboratory-prepared routine compounds can then be tested {or solubility and, generally speaking, this is all that is required to give a suitable variety covering the hydrophile- All these tests, stated, are intended to be routine tests and nothing more. They are intended to teach a person, even though unskilled in oxyethylation or oxyalkylation, how to prepare in a perfectly arbitrary manner, a series of compounds illustrating the hydrophilehydrophobe range.

If one purchases a thermoplastic or fusible resin on the open market selected from a suitable number which are available, one might have to make certain determinations in order to make the quickest approach to the appropriate oxyalkylation range. For instance, one should know (a) the molecular size, indicating the number of phenolic units; (12) the nature of the aldehydic residue, which is usually CH2; and (c) the nature of the substituent, which is usually butyl, amyl, or phenyl. With such information one is in substantially the same position as if one had personally made the resin prior to oxyethylation.

For instance, the molecular weight of the internal structural units of the resin of the following over-simplified formula:

(11.21 "to 13, or even more) identical with the recurring internal unit except that it has one extra hydrogen. The right-hand terminal unit lacks the methylene bridge element. Using one internal unit of a resin as the .basic Previous reference has been made to e1emnt,'a'resins molecularweight is given approximately by taking (n plus 2) times the weight of the internal element. Where the resin molecule has only 3 phenolic nuclei as in the structure shown, this calculation will be in error by several per cent; but as it grows larger, to contain 6, 9, or 12 phenolic nuclei, the formula comes to be more than satisfactory. Using such an approximate weight, one need only introduce, for example, two molal weights of ethylene oxide or slightly more, per phenolic nucleus, to produce a productof minimal hydrophile character. Further oxyalkylation gives enhanced hydrophile character. Although we have prepared and tested a large number of oxyethylated products of the type described herein, we have found no instance where the use of less than 2 moles of ethylene oxide per phenolic nucleus products.

Examples 1b through 18b and the tables which appear in columns 51 .through 56 of our said Patent 2,499,370 illustrate oxyalkylation products from resins which are useful as intermediates for producing the esterified products of the present invention, such examples giving exact and complete details for carrying out the oxyalkylation procedure.

The resins, prior to oxyalkylation, vary from tacky, viscous liquids to hard, high-melting solids. Their color varies from a light yellow through amber, to a deep red or even almost black. In the manufacture of resins, particularly hard resins, as the reaction progresses the reaction mass frequently goes through a liquid state to a sub-resinous or semi-resinous state, often characterized by being tacky or sticky, to a final complete resin. As the resin is subjected to oxyalkylation these same physical changes tend to take place in reverse. If one starts with a solid resin, oxyalkylation tends to make it tacky or semiresinous and further oxyalkylation makes the tackiness disappear and changes the product to a liquid. Thus, as the resin is oxyalkylated it decreases in viscosity, that is, becomes more liquid or changes from a solid to a liquid, particularly when it is converted to the water-dispersible or water-soluble stage. The color of the oxyalkylated derivative is usually considerably lighter than the original product from which it is made, varying from a pale straw color to an amber or reddish amber. The viscosity usually varies from that of an oil, like castor oil, to that of a thick viscous sirup. Some products are waxy. The presence of a solvent, such as 15% xylene or the like, thins the viscosity considerably and also reduces the color in dilution. No undue significance need be attached to the color for the reason that if the same compound is prepared in glass gave desirable and in iron, the latter usually has somewhat darker color. If the resins are prepared as customarily employed in varnish resin manufacture, i. e., a procedure that excludes the presence of oxygen during the resinification and subsequent cooling of the resin, then of course the initial resin is much lighter in color. We have employed some resins which initially are almost waterwhite and also yield a lighter colored final product.

Actually, in considering the ratio of alkylene oxide to add, and we have previously pointed out that this can be predetermined using laboratory tests, it is our actual preference from a practical standpoint to make tests on a small pilot plant scale. Our reason forso doing is that we make one run, and only one, and that wehave a complate 'series'twhich' shows-"the progressive effect of introducing. the oxvalkylating agent, for instance,

the ethyleneox radicals. Our preferred procedure is as follows: We prepare a suitable resin, Iorfor that matter, purchase it in the open mar- .ket. We employ 8 pounds of resin and 4 pounds :ef xylene and place the resin and xylene in a suitable autoclave with an open reflux condenser. -We prefer to heat and stir until the solution is complete. We have pointed out that soft resins which are fluid or semi-fluid can be readily'prepared .in various ways, such as the use of orthotertiary amylphenol, ortho-hydroxydiphenyl, 'ortho decylphenol, or by the use of higher molec- Zu-lar weight aldehydes than formaldehyde. If such resins are used, a solvent need not be added but may be added as a matter of convenience ro'r -for comparison, if desired. We then add a catalyst, for instance, 2% of caustic soda, in the form of a .20%'to 30% solution, and remove the water'of solution or formation. We then shut ofi the reflux-condenser and use the equipment as an autoclave onlyyand oxyethylate until a total :of 60 pounds of ethylene oxide have been added, equivalent to 750% of the original resin. We .prcfer'a temperature of about 150 C. to 175 C. We also take samples at intermediate points as indicated in the following table:

Pounds of Ethylene Oxide Added per Percentages 8-pound Batch Oxyethylationto 750% can usually be completed within 30 hours and frequently more quickly.

1 The samples taken are rather small, for instance, 2 to 4 ounces, so that no correction need be made'in regard to the residual reaction mass. Each sample is .divided in two. One-half the sample is placed in an evaporating dish on the steam bath overnight so as to eliminate the xylene. Then 1.5% solutions are prepared from both series of samples, i. e., the series with xylene present and the series with xylene removed.

Mere visual examination of any samples in solution may be suflicient to indicate hydrophile character or surface activity, i. e., the product is soluble, forming a colloidal sol, or the aqueous solution foams or shows emulsifying property. All these properties are related through adsorption at the interface, for example, a gas-liquid interface or a liquid-liquid interface. If desired, surface activity can be measured in any one of the usual ways using a Du Nouy tensiometer or dropping pipette, or any other procedure for measuring interfacial tension. Such tests are conventional and require no further description.

Any compound having sub-surface-activity, and all derived from the same resin and oxyalkylated to a. greater extent, i. e., those having a greater proportion of alkylene oxide, are useful for the practice of this invention.

Another reason why we prefer to use a pilot plant test of the kind above described is that we can .use the same procedure to evaluate tolerance '16 towards a trifunctional phenol such as hydroxybenzene or metacresol satisfactorily. Previous ref erence has been made to the fact that one can conduct a laboratory scale test which will indicate whether or not a resin, although soluble in solvent, will yield an insoluble rubbery product, i. e., a product which is neither hydrophile nor surface-active, upon oxyethylation, particularly extensive oxyethylation. It is also obvious that one may have a solvent-soluble resin derived from a mixture of phenols having present 1% or 2% of a trir'unctional phenol which will result in an gestion of rubberiness.

insoluble rubber at the ultimate stages of oxyethylation but not in the earlier stages. In other words, with resins frem some such phenols, addition of 2 or 3 moles of the oxyallcylating agent per phenolic nucleus, paiticularly ethylene oxide, gives a surface-active product which is perfectly satisfactory, while more extensive oxyethylation yields an insoluble rubber, that is, an unsuitable product. It is obvious that this present procedure of evaluating trifunctional phenol tolerance is more suitable than the previous procedure.

It may be well to call attention to one result which may be noted in a long drawn-out oxyalkylation, particularly oxyethylation, which would not appear in a normally conducted reaction. Reference has been made to cross-linking and its effect on solubility and also the fact that, if carried far enough, it causes incipient stringi ness, then pronounced stringiness, usually followed by a semi-rubbery or rubbery stage. Incipient stringiness, or even pronounced stringiness, or even the tendency toward a rubbery stage, is not objectionable so long as the final product is still hydrophile and at least sub-surface-active. Such material frequently is best mixed with a polar solvent, such as alcohol or the like, and preferably an alcoholic solution is used. The point which we want to make here, however, is this: Stringiness or rubberization at this stage may possibly be the result of etherification. Obviously if a difunctional phenol and an aldehyde produce a non-cross-linked resin molecule and if such molecule is oxyalkylated so as to introduce a plurality of hydroxyl groups in each molecule, then and in that event if subsequent etherification takes place, one is going to obtain crosslinking in the same general way that one would obtain cross-linking in other resinification reactions. Ordinarily there is little or no tendency toward etheriiication during the oxyalkylation step. If it does take place at all, it is only to an insignificant and undetectable degree. However, suppose that a certain weight of resin is treated with an equal weight of, or twice its weight of, ethylene oxide. This may be done in a comparatively short time, for instance, at l50 or 175 C. in 4 to 8 hours, or even less. On the other hand, if in an exploratory reaction, such as the kind previously described, the ethylene oxide were added extremely slowly in order to take stepwise samples, so that the reaction required 4 or 5 times as long to introduce an equal amount of ethylene oxide employing the same temperature, then etherification might cause stringiness or a sug- For this reason if in an exploratory experiment of the kind previously described there appears to be any stringiness or rubberiness, it may be well to repeat the experiment and reach the intermediate stage of oxy- -alkylation as rapidly as possible and then proceed slowly beyond this intermediate stage. The entire purpose of this modified procedure is to cut down the time of reaction so as to-avoid etherifi- 1'7 cation if it be caused by theextended time period; It may be well to note onepeculiarreaction sometimes noted in the course of'oxyalkylation, particularly oxyethylation, of the thermoplastic resins herein described. This eflec't noted in a case where a thermoplastic resin has been oxyalkylated, for instance, oxyethylated. until it gives a perfectly clear solution, even in thepresence. of some accompanying water-insoluble sol'vent su'ch as to of xylene. Further ox yalkylation, particularly oxyethylation, may thenyield aprodnot which, instead ofgivlng -a clear solution as previously, gives a very milky-sol'ution'suggest ing that some marked change has taken place. One explanation of the above change is that the structural unit indicated-in the fOHOWiHg WaY where 8n is a fairly large number, for instance, 10 to 20, decomposes and an oxyalkylated resin representing a lower degree of 'oxyethylation and a less soluble one, is generated and'a cyclic polymer of ethylene oxide isproduced, indicated thus:

reason that oxyalkyl'ation can be conducted in each instance stepwise, orat a gradual rate, and samples taken at short intervals so as toarrive at a point whereoptimum surface activity or hy-j drophile character is obtainedif desired; for products for use in the practice of this invention, this is not necessary and, in fact,'mayf-beundes'irable, i. e., reduce the eihciencyof the product. J y We do not known to what extent oxyalkylation produces uniform. distribution in regard to phe nolic hydroxyls' present in the resin molecule. In'some instances, of course, such' distribution can not be uniform for the reason that we have not specified that the molecules of ethylene oxme, for example, be added; in multiples of the units present in the resin moleculei" This maybe illustrated inthe followingmannerf j Suppose the resin happens to have five phenolic nuclei. If a minimum of two moles of ethylene oxide per phenolic'nucleus are added, this would mean'an addition of 10 moles of ethylene oxide, but'suppose thatone' added 11 moles of ethylene oxide, or 12, or 13, or 14 moles; obviously, even assuming the most uniform distribution possible; some ofv the polyethyleneoxy radicals would contain 3 ethyleneoxyunits and somewould contain; 2. Therefore, it is'impossible to specify uniform distribution in regard to the entrance of the; ethylene oxide orother oxyalkylating' agent. For that matter, if one were'to introduce moles of ethylene oxidethere is no waytb' be certain that all chains would have 5 units; there might be some having, for example, 4" and 6units, or for that matter 3 or Nor isthereany basis for'assuming that the number of molecules" of the oxyalkylating agent added each offthe molecules of the resin is the same; 'or'diflerentr Thus;

This fact, of course, presents no difliculty' forthe whereformulae are given to illustrate or depict the oxyalkylated products, distributions of radicals indicated are to be statistically taken. We have, however, includedspecific directions and specifications in regard to the total amount of ethylene-oxide, or total amount of any other city-- alk'ylating'agent,tda'dd'. f r

regard tosolubilityof the resins and the oxyalkylated'compounds, and for that matter derivatives of the latter, the following should be noted. In oxyalkyl'ation, any solvent employed should be non-reactive to the alkylene'cxide employed. This limitation does not-"apply to selvents used in cryoscopic determinationsfor obvious reasons. Attention is directed to the fact that various organic solvents may be employed to verify that the-resin is'org'anic' solvent-soluble. Such solubility test merely characterizes the resin. The particular solvent used in such test may not be suitablefora molecular weight determination and, likewise-,"the solvent used in determining molecular weight may not be suitable as a'solvent during oxyalkylation. For solution of the oxyalkylated compounds, or their derivatives a greatvariety of solvents may be employed, such as alcohols, ether alcohols, cresols', phenols, ketones, esters, etc., alone or with the addition of water. Some of these are mentioned hereafter. We prefer the" use of'benzene or 'diphenylam'ine as a solvent in: making cryoscopic measurements. The most satisfactory resins are those which are soluble in xylene or the like, rather than those; which are soluble only in some other solvent containing elementsother than carbon and hydrogen, for instance; oxygen or chlorine. Such solvents are usually pclar,"semi-polar, or slightly polar in nature compared with xylene, cymene. etc.

Reference to cryoscopic measurement 1'sv concerned' with the use of benzene or other suitable compound as a solvent. Such method will. show that conventional resins obtained, for example, from para-tertiary amylphenol and formaldehyde in presence of an acid catalyst, will'have a molecular weight indicating 3, 4", 5' or somewhat greater. number of structural units per molecule. If more drastic conditions of resinification are employed or if such low-stage resin subjected to a vacuum distillation treatment as previously described, one obtains a resin of a distinctly higher molecular weight. Any molecular weight determinationused, whether cryoscopic measurement or otherwise, other than the cinventional cryo-' scopic-one employing benzene, should be checked so as to insure that it gives consistent values on such conventional resins as a control. Frequently all that is necessary to make an approximation of the molecular weight range is to make a, com parison with the dimer obtained by chemical combination of'two moles of the same phenol, and onemole of the same aldehyde under conditibns to insure dimeriz'ation. As to the preparation' of such dimers from substituted phenols, see Carswell, "Phenop1asts,' page 31. The increased viscosity, resinous character, and decreased solubility, etc, of the'higher'polymers in comparison with the dimer; frequentlyare all that is required to establish that'the resincontains 3 or more structural units per molecule.

Ordinarily, the oxyalkyl'ation-is carried'out in autoclaves rovided with agitators or stirring devices. We have found that'the speed of the agitation markedlyinfluences the time reaction. In somecases', the change from slow speed agitation, for example, in a laboratory autoclave 19 agitation with a stirrer operating at a speed of 60 to 200 R. P. M., to high speed agitation, with the stirrer operating at 250 to 350 R. P. M., reduces the time required for oxyalkylation by about one-half to two-thirds. Frequently xylenesoluble products which give insoluble products by procedures employing comparatively slow speed agitation, give suitable hydrophile products when produced by similar procedure but with high speed agitation, as a result, we believe, of the reduction inthe time required with consequent elimination or curtailment of opportunity for curing or etherization. Even if the formation of an insoluble product is not involved, it is frequently advantageous to speed up the reaction, thereby reducing production time, by increasing agitating speed. I In large scale operations, we have demonstrated that economical manufacturing results from continuous oxyalkylation, that is, an operation in which the alkylene oxide is continuously fed to the reaction vessel, with high speed agitation, i. e., an agitator operating at 250 to 350 R. P. M. Continuous oxyalkylation, other conditions being the same, is more rapid than batch oxyalkylation, but the latter is ordinarily more convenient for laboratory operation.

Previous reference has been made to the fact that in preparing esters or compounds of the kind herein described, particularly adapted for demulsification of water-in-oil emulsions, and for that matter for other purposes, one should make a complete exploration of the wide variation in hydrophobe-hydrophile balance as previously referred to. It has been stated, furthermore, that this hydrophobe-hydrophile balance of the oxyalkylated resins is imparted, as far as the range of variation goes, to a greater or lesser extent to the herein decribed derivatives. This means that one employing the present invention should take the choice of the mostsuitable derivative selected from a number of representative compounds, thus, not only should a variety of resins be prepared exhibiting a variety of oxyalkylations, particularly oxyethylations, but also a variety of derivatives. 7 This can be done conveniently in light of what has been said previously; From a practical standpoint, using pilot plant equipment, for instance, an autoclave having a capacity of approximately three to five gallons. We have made a single run by appropriate selections in which the molal ratio of resin equivalent to ethylene oxide isone to one, 1 to 5, l to 10, l to 15, and l. to 20. Furthermore, in making these particular runs we have used continuous addition of ethylene oxide. In the continuous addition of ethylene oxide we have employed either a cylinder of ethylene oxide without added nitrogen, provided that the pressure of the ethylene oxide was sufllciently great to pass into the autoclave, or also we have used an arrangement which, in essence, was the equivalent of an ethylene'oxide cylinder with a means for injecting nitrogen so as to force out the ethylene oxide in the manner of an ordinary Seltzer bottle, combined with the means for either weighting the cylinder or measuring the ethylene oxide used volumetrically. Such procedure and arrangement for injecting liquids is, of course, conventional. The following data sheets exemplify such operations, i. e., the combination of both continuous agitation and taking samples so as to give five different variants in oxyethylation. In adding ethylenev oxide continuously, there is one precaution which must be taken at all times. The addition of ethylene oxide must stop immediately if there is any. indication that reaction is stopped or, obviously, if reaction is not started at the beginning or the reaction period. Since the addition of ethylene oxide i invariably an exothermic reaction, whether ornot reaction has taken place can be judged in the usual manner by observing (a) temperature rise or drop, if any, (b) amount ofcooling water or other means required to dissipate heat of reaction; thus, if there is a temperature drop without-the use of cooling water or equivalent, or'if there is no rise in temperature without using cooling water control, careful investigation should be made.-

In the tables immediately following we are showing the maximum temperature and usually the operating temperature. In other words, by experience we have found thatlif the initial reactants are raised to the indicated temperature and then if ethylene oxide is added slowly, this temperatureis maintained by cooling water until the ,oxyethylation is complete. We have, also indicated the maximum pressure that we obtained or the pressure range. Likewise, we have indicated the time required to injectthe ethylene oxide as well as a brief note as to the solubility of the product at the end of the oxyethylation period. As one period ends it will be noted we have removed part of the oxyethylated mass to give us derivatives, as therein described; the rest has been subjected to further treatment. All this is apparent by examining the columns headed Starting mix, Mix at end of reaction," Mix which is removed for sample, and Mix which remains as next starter.

The resins employed are prepared in the manner described in Examples 1a through 1030. of our said Patent 2,499,379, except that instead of being prepared on a laboratory scale they were prepared in 10 to ill-gallon electro-vapor heated synthetic resin pilot plant reactors, as manufactured by the Blaw-Knox Company, Pittsburgh, Pennsylvania, and completely described in their Bulletin No. 2087 issued in 1947, with specific reference to Specification No. 7 1-3965.

For convenience, the following tables give the numbers of the examples of our said Patent 2,499,370 in which the preparation of identical resins on laboratory scale are described. It is understood that in the following examples, the change is one with respect to the size of the operation.

The solvent used in each instance was xylene. This solvent is particularly satisfactory for the reason that it can be removed readily by distillation or vacuum distillation. In these continuous experiments the speed of the stirrer in the autoclave was 250 R. P. M.

In examining the subsequent tables it will be noted that if a comparativelysmall sample is taken at each stage, for instance, to one gallon, one can proceed through the entire molal stage of 1 to 1,.t0 1 to 20, without remaking at any intermediate stage. This is'illustrated by Example 1041;. In other examples we found it desirable to take a larger sample, for instance, a 3-gallon sample, at an intermediate stage. As a result it was necessary in such instances to start with a new resin sample in order to prepare sufiicient oxyethylated derivatives illustrating the latter stages. Under such circumstances, of course, the earlier stages which had been previously prepared were by-pas'sed or ignored. This is illustrated in the tables where, obviously, it shows that'the starting mix was not removed from a previous sample.

22 Phenolfor resin: Para-tertiary amylphenol Alde'hydejor resin: Formaldehyde [Resin made inpilot plant size batch, approximately 25 pounds, corresponding to 309! Patent.2,99,370 bu; this} batch designated 1040.]

Mix Which is, Mix Which Rer i Mi ggfigg of Removed for mains as N at f Sample Starter Max. Max. Time Pressure, Temp era- Solubility Lbs. Lbs; .Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. "9 Sol- Resg Sol- Res- Soi- -Res- Sol- Resvent in o vent in vent in yent' in t First Stage ResintoEtO M0181 Ratio 121.- 14.25 15.75 0 14.25 -15. 4.0 3.35 3.05 1.0 10.9 12.1 3.0 150 H I I 111.110.1040---. :1

Second Stage Resin to Et0 Molal Ratio 1:5 10 9 12.1 3.0 10.9 12.1 15.25 3.77 4.17 5.31 7.13 1 1.93 1 0.04 70 158 3'2 5'1 Ex. No. l05b Third Stage Resin to EtO Molal Ratio 1:10 7.13 7. 93 9.94 7.13 7.93 19.69 3. 29 3.68 9.04 8.84 4.25 10. 65 60 173 ii Ex. N0.106b-.. j

Fourth Stage Resinto EtO M0101 R8510 1:15- 8.84 4.25 10.05 3.114 4.21 10.15 2.04 2.21 8.55 1.80 2.04 2.00 220 1001 n 1 Rs 1 Ex. N0. 107b i Fifth Stage Resin to Et0. 1 v Molal Ratio 1: }1.80 2.04 7.00 1.80 2.04 10.2 150 I 5 Q81 Ex. No. 108b f I==Insoluble. ST=Sligi1t tendency toward becoming soluble. FB==Fairly solub1e m 1205011, soluble.

oe- 0110 soluble.

Phenoifor resin: Nony lpher ol- 1 Aldehyde for ..reein; .Earmaldehydc:

[Resin made in piiotplant size bat ch, approximately 25 pounds, corresponding 10- 7000! Patent.2 499,370 bnt this hotel; deaignated 100a.)

Mix Which is Mix which I Starting M1: 31 3333 Removed m mains as Nan.

. Sample Starter Max. Max. Time 7 v Pressure, vTemnemhm Solubility g Lbs v Ifibs. Lbs g a Lbs lbs. sq. in. .ture. O. 0- eso- -eS- ,o- -aso- -08- vent 111 m0 vent 111 3 .11: in E v nt m F First Stage Resin to EtO. Moial Ratio 1; 15.0 15 0 .0 15.0 10.0 a 5.0. 0.0-

1.0 10.0 10.0 2.0 a0 1% Mr. XNOJOQb h 7 Second Stage Resin to 1:10.--- Mola] Ratiolrfin; 10 10 2.0 10 10 9.4 2.72 2.72 2.56 7.27 7.27 0.86 100 147 2 1)! Ex. No. 110b-...-

Third Stage Resin to EtO 1 Molal Ratio 1:10.- 7. 27 7.27 6.86 7.27 7.27 13.7 4.16 4.16 7.68 3.15 3.15 5.95 125 1!, 8' Ex. No.111b... 8

Fourth Slade Resin to EtO.. MoIa1Rati01:15. 3.15 3.15 5. 95 3.15 3.15 8.95 1.05 1.05 2.95 2.10 2.10 I 6.00 220 174 I 2% I S EX.N0.112b

Fifth Stage Resin to Et0... I Molal 1101101120.. 2.10 2.10 0.00 2.10 2.10 8.00 220 1 183 vs Ex. No.113b v 0 V A. V I -S=Soiub1e. S'1.=$J-ligl1t tendencyioward solubility. DT -Definite tendency toward solubility. I

. .ysavergsolubie:

;.Ph'enol for resin: Pam-octylphenol Aldehyde for resin: Formaldehyde mgn'. nlloi'flnnt size baton, approximntelv 25 pounds,'corresponding to So of Patent 2,499,370 bui this batch designated 114m] Muwmcnis MixWhlchRe- Starting Mix figf figg Removed'tor mains as Next 1 Sample Starter I Max. Max. Time lrgressurig. 'tlemp ergms Solubility Lbs Lbs s. Lbs. .Lbs Lbs Lb's. Lbs. Lbs.

Lbs Lbs. -Lbs Lbs Bol- Res- Sol- .Res- 301- Res- Soi- Besvent in Etc vent in Em vent in E vent in Eto First Stage ReSintoEtOL... M01111 Ratio 1.1.- 14.2 15.8 -'0 14.2 15.8 3.15 3.1 3.4 0.75 11.1 12.4 2.5 150 1%: NS Ex. No. 114b Second Stage Resin to EtOl.-- Molal'Ratio 1:5 11 1 12.4 2.5 11.1 "12.4 12.5 7.0 7.82 7.88 4.1 4.58 4.62 171 14 88 Ex. No. 1155.....

Third Stage Besinto 1110.... r MolnlBatiohlou 6.64 7.36 '0 5.64 7.36 15.0 190 1% B Ex.No.116b

Four Stage Resinto 1520-.-- I Molar Ratioklb- 4.40 1.9 0 4.4 4.9 14.8 400 M VB Ex. No. 1175..-.-.

Fifth Stage Resin-to EtO.-- a v MolalRntiolzZfl... 1 4.58 1:5 4.1 4.58 18.52 250 172 )4 VS Ex. No. 1185-.-

D Phenol for nm'm' 'Menthylphenol Aldehyde for resin." Forfnuldehyde ate (Resin made in pilot plant size batch, approximately 25 pounds, corresponding to 69 oi Patent 2,499,370 but this batch designntad 119a.)

Mix Which is M1! which Ro- Starting Mix gg fifig Removed for mains as Next 7 Sample Starter Max. Max. Time 7 Pressure, Temp era- Solubility 1 11 libs. Lbs gbls. libs. Lbs 15:18. I bs. 1 11 5. libs. Lbs i 0- es- 0- eses-' 0- es vent in E10 vent in Em vent in Eto vent in mm Stage nesmjm 1210--.- V i Molal'Ratio 1:1.-. 13.55 16.35 0 13.85 16. 35 3.0 9.55 11.45 2.1 4.1 4.9 0.9 50 150 1% NS Ex. No. 1195...

Second Stage Resin to Et0... Molsl"Ratio1:5..' 10 12 0 10 12 10.75 4.52 5.42 4.81 5. 48 6.58 5.94 140 1342 8 Ex. No.120b-.--.

Third Stage Resin to EtO i i 11401811181101 5.48 5.58 5.94 5.48 6.58 10.85 90 150 34 8 Ex. No. 1215.-

Fourth Stave Besinto Et0 M0151Rat1011 4 1 4.9 11.9 4.1 4.9 13.15 18-0 171 1%: VS Ex. No. 122b.---.

Fifth Stage Resinto E105-" M0131 Ratio L20 3.10 3. 72 0.68 3.10 3.72 13.43 320 35 V8 Emma-2311..

S-Soluble. NB-Notsoluble. VS-Verysoluble.

Phenol for resin: Pam-secondary butylphen'ol [Resin made in pilot plant size batch, approximately 25 pounds,

Aldehyde for res-in: Formaldehyde Mix Whieh is Mix Which Re- Starting Mix fig ggg Removed for mains as Next Sample Starter Max Max Time Pressui e, Temgera Solubility I b s. I bs. Lbs l 'b s. lIibs. Lbs lbls. abs. Lbs Ibls. gbs. Lbs

oas o-esoes- 0-,esvent in Eto vent in me vent in vent in Eto First Stage Resin to EtO. M0111 Ratio 121-. 14.45 15.55 0 14.45 15. 55 4.25 5.97 6.38 1. 75 8.48 9.17 2.50 60 150' 942 NS Ex. No. 1246- Second Stage ResintoEt0 M0151 Ratio 1:5 8.48 9.17 2.50 8.48 9.17 16.0. 5.83 6.32 11.05 2.65 2.85 4.95 95 188 16. SS Ex. N0. 1255.....

Third Stage Resin to Et0 M0181 Ratio 1:10.. 4.82 5.18 0 4.82 5.18 14.25 400 183 t S Ex. No. 1265.....

Fourth Stage Resin to Et0--.- .MoialRatio1:15.. 3.85 4.15 0 3.85 4.15 17.0 120 180 56 VS Ex. No. 127b..

Fifth Stage Resin to Et0 Mo1alRati01:20- 2.65 2.85 4.95 2.65 2.85 15.45. 80 170 91: VS Ex. No. 128b S-Soluble. NS-Not soluble. SS-Somevirhat soluble. VS-Very soluble.

[Resin made on pilot plant size batch, approximateiyfli pounds, corresponding to 81a of Patent 2 Phenol for resin: Menthyl Aldehyde for resin: Propionaldehyde ,499,370 but this batch designated 129a.]

Mix Which is Mix Which Re Starting Mix ggf figg Removed for mains ss Next Sampie taster Max. Max. Time I v Pressuge, Temgerahm Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Q- Soi- Res- E- 801- Res- 3 3; 801- Res- 3B? 801- Resg vent in vent in vent in vent in First Stage ResintoEt0 I I M0151 Ratio 1:1... 12. 8 17. 2 12. 8 17. 2 2. 75 4. 5. 7 0. 95 8. 55 11. 1. 80 110 150 )6 N01. soluble. Ex. No. 1296.....

Second Stage Resin to EtO M0151 Ratio 1:5-. 8. 11. 5O 1. 8. 55 11. 50 9. 3 4. 78 6, '12 5. 2 3. 77 5. 08 4. 10 170 $6 somewh at Ex. No. 13%.. soluble.

Third Stage Resin to EtO. M0151 Ratio 1:10.. 3. 77 5. 08 4. 10 3. 7.7 5. 08 13. 1 100 182 M2 soluble. EX. N0. 131b.-.-

Fourth Stage Resin t0 EtO... M0181 Ratio 1:15-. 5. 2 7. 0 5. 2 7. 0 17. 0 2. 1,0 2. 83 6. 87 200 182 M Very soluble. Ex. No. 132b.

Fifth Stage Resin to Et0.. I 1 v M0131 R8tio1'20 .2. 10 2. 83 6. 87 2. 10 2.83 9. 12 90 D0. Ex. N0. 1331...--. i

Phenol for. rsin: Para te'rt'iary amylphenni Aldehydeforresim Fui'jural' [Resinmarle on pilot plant size batch, approximately 25 pounds; corresponding to 4211' of Patent 2,499,370 but'this batch designated as 1340.]

. Mix Which is Mix Which Re- Starting Mix figg fi g of Removed for main! as Next Sample Starter Max. M ax lgressmia, 'tlemp ergg Solubility Lbs Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs

Lbs. Lbs. Lbs Lbs. Sol- Res- Sol- Res- S01- Res- Sol- Resvent in E10 vent in E150 vent in Eto vent in Etc First Stage ResintoEtO- i Moial Ratio 1:1"- 11. 2 18.0 11.2 18. 0 3. 5 2. 75 4. 4 0. 85 8.45 13. 6 2. 55 120 135 5 Not soluble. Ex.N0.134b

Second Stage ResintoEtO Molal Rat101z5--- 8.45 13.6 2.65 8.45 13.6 12.55 5.03 8.12 7.55 8.& 5.48 5.10 110 150 )4 Somewhat Ex. No. 1355.. soluble.

Third Stage Resin to EtO- Mala! Ratio 1:10-- 4. 5 8. 0 4. 5 8. 0 14. 5 2. 5. 35 7. 99 2. 05 3. 65 v 6. 60 180 163 $5 Soluble. Ex. No. 1360"..-

Fourth Stage Resin to EtO Moiai Ratio 1 3. 42 5. 48 5. 10 3. 42 5. 48 15.10 180 188 Very soluble. Ex. No. 1375- Fifth Stage Resin to EtO Moial Ratio 1:20.. 2. 05 3. 65 6. 2.05 3. 13. 35 120 125 95 Do. Ex. No. 138b.

[Resin made on pilot size batch, approximately 25 p Phenol for resin: M enthyl Aldehyde for resin: Furfural ounds, corrasponding to 89a of Patent 2,499,370 but this batch designated as 139%] Mix Which is Mix Which Re- Starting Mix figg figg of Removed for main. as Next Sample Startar Max. Max. Time ligressm e, 'tllgmpgtahrs Solubility Lbs Lbs. Lbs. Lbs Lb. Lbs. Lbs Lbs.

Lbs. Lbs. Lbs Lbs. Sol- Res- Sol- Res- Sol- Res- Sol- Besvent in Eto vent in Eto vent in Eto vent in Eto Firat Stage Resin to Et0- M01131 Ratio 1:1" 10. 25 17. 10. 25 17. 75 2. 5 2. 65 4.60 0. 65 7.5 13. 15 1. 150 )6 Not Ex. No. 1395-- soluble. Second Stage Rosin to 110.... M01211 Ratio 1:5-. 7.6 13.15 1.85 7.6 13.15 9.35 5.2 9.00 6.40 2.4 4.15 2.95 80 177 )6 Somewhat Ex. No. 140b V soluble.

Third Stage Resin to EtO- M0121 Ratio 1: 10.- 4. 22 6. 98 4. 22 6. 98 10. 0 90 1B5 16 80101110. Ex. N0. 1415--."

Fourth Stage Resin to 1510....

M013! Rat1o1:15-- 3 75 6. 24 3. 76 6. 24 13.25 100 171 56 V61 ,Ex. No. 1425"--. solub a.

Fifth Stage Resin to 15120.... M0181 Ratio 1:20.- 2. 4 4. 15 2. 95 2. 4 4.15 11. 70 90 H D0. Ex. No. 1435.--..- h 1 Phenol for resin: Para-octyl Aldehydejor resin? Furjurab [Resin made on pilot plant size batch approximately 25 ponnds, commanding to 420 of Patent 2,490,370 with 206 parts by weight cummereial pare'octylphenol repl'acinglm parts by weight of para-tertiary amylphenol but this batch designated as 1440.]

Mix-which i Mix Which Tle- Starting Mix' g figg of Removed {or mains a Next Sample Starter M Max,

. I Time I Pressure, Tempgre hm Solubility 1 .11 5. ns. Lb: 1 .0 5. a s. Lbs 1 .2 5. gm. 1 .0 abs. Lbs l t i f o 05- 0- eses- 0- esr vent in Eto vent i111 Eto vent in Eto vent in Etc First Stage ResintoEt0.-- .r M0181 Ratio 1:1... 12 1 18. 6 12. 1 18. 6 3. 0 5. 38 8. 28 1. 34 6. 72 10. 32 l. 66 80 150 H: Insoluble. Ex. No. 1446"..-

Second Stage v Q v V Slight Resin to Et0. I 1 1 easy to- Molfil Ratio 1:5... 9 14. 25 9. 25 I4. 25 11. 0 3. 73 5. 7,3 4. 44 5. 52 8. 52 6. 56 100 177 9i: wand Ex.No.145b... coming "soluble.

Third Stay:

ReaintoEt0..-. M0151 Ratio 1:10-. '6 72 10. 32 1. 66 0. 72 10. 32 14. 91 4. 97 7. 62 11. 01 1. 75 2. 3. 90 85 182 M .Feirly 50111- Ex. No. 1460... ble.

Fourth Stage ResintoEtO Y f M0181 Ratio 1 5. 52 8. 52 6. 56 5. 52 8. 52 19. 81 100 176 $6 Reedilysolw Ex. N0. 1470- I ble.

Resin toEtonn Y M0181 Ratio 1:20.. 1 2. 70 3. 9O 1. 75 2. 70 8. 4 160 M Quite" Sollb Ex. No. 1486... V ble.

Phenol for ifs sin." Pam-phenyl V Aldehyde for 1 01511.: Fui'jufdl I [Resin made 1 p l t gi nt size b tch, pproiimate'ly 25 po n s. 0011555501115 t6 42a 01 Patent 240031021215 110 per ump is by weight 01 00111111010121 enylphenol replacmg 164 gents by weig ht 0i pare-tertiary amylphenol but this batch designated as 1492.]

, mxwh'miiis MixWhi'c h Il0- Starting Mix gg figg Removed for mains as Next Sample Starter 7 Max. Max. ,Time

- 7 53 Presel my "Ieznp ere'. Solubility 1 .0 3. gins. Lbs 1 .5 8. l bs. Lbs 1 .15;. fibs. Lbs 1 .5 8. 55. Lbs e 0- es- 0- es- 0- es: 0- esvent in Eto vent in Em vent in Eto vent in Eto Second Stage Resin to 1:10.- gfg igj 510121112201... 10.35 12.45 2.20 10.35 12.15 12.20 5.15 5.19 0.00 5.20 0.20 0.14 so 183 15 wardmlm Ex. N0. 1505.-." m

Third Stage ResmtoEtO w Molal Retio1:10-- s 10.? 8.90 10.10 10.0 5.30 0.33 11.32 3.50 4.32 1.05 00 193 "A: Fair splu- Ex. No. l51b-. I l 1 ble. 1

Fourth Stage Molal Ratio 1:15.. 6. 26 6. 14 6. 20 6. 26 16. 64

Ex. N0. 162b-.---

Fifth Szaqa Resin to 121.0.

Sample somewhat rubbery and 30- Molal Rat1o1.20.. 3.60 4. 32 7.68 3.60 4.32 16.68 Ex. No. .hflholill butfairlyslolubial- R int 1:00-... es }520 111 14 Readily so]- I .ubl9.'--

PhenoZfor-r''aifi Przra nohglph enol Aldefigde fi'siriFFurfural {Resin made on ilot-plant 155551511, approximately 25 pounds, corresponding 55 88a of Patent 2.490;.370 bin 111151551 11 deeigneteii 15421.1

v Mix which is, Mix Which Re- Starting Mix Mix at End Removed for mains eeNext v Reaction Sample Starter Mex. Max. Time H I I Pressure, Temaera- Solubility 25-1 255 -55 -5 0 0 ee- 0 0 65- vent in Em vent in Etc vent in Eto vent in Em First Stage ResintoEtO--.- MolalBatiolzl 10.85 20.75 10.85 20.75 3.0 2.57 4,90 0.73 8.28 15.35 2.27 55 insoluble. Ex."No.154b I 1 Second Stage Slight Resin to BK). tendency Mo1alRatio1:5 8.28 15.85 2.27 8.28 15.85 11.77 3.82 7.33 5.45-4.45 8.52 0.a2 I 100 182 55 toward Ex. No;b... becoming v j soluble. Third Stage 11551111511500 M0151 115115130 5.95 11.35 5.25 11.35 16.75 3.35 0.42 0.50 2.57 4.95 7.25 100 181 I 15 Fairly Ex. No. 1566... I soluble.

Fourth Stage ResintoEt0.. Mo1alRetio1:16 4.16 2.52 0.32 4.40 8.62 19.07 90 188 34s Readily Ex. No. 16712..." V r soluble. my! Stage Resin to Et0--.. M5151 Rat1o1 :20-- 2.57 1.05 7.25 2.57 4.90 14.50 4 100 160 55 Quite Ex. No.158b..--- soluble.

Phenol for resin: Para-phenylphenol Aldehydofor rqein: Formaldehyde [Resin made on pilot pl ant size batch, approximately 25 pounds, correeponding to 92 of Petent 2,499.370 but this batoh le sig natedee 15911. 1

7 M'ixwhichie Mixvvmmne- Starting Mix figg ggg Removed (or mains as Next Sample Starter Max. Max

Pressure, Tempgeraag? Solubility 8 2? g Lb fi Lbs libs. Lbs S g Lbs ibs.sq.m. ture, O.

eso- 25- 0- es- 0- esvent in Em Eco vent Em vent in Em vent 1n Fix-5t Stage Resin to EtO- Mole! Ratio 1 Ex. No

Second 52 11x. No.159b

Third Stage Resin to 1210--.-

}11.0 9.0 11.0 9.0 11,75 7.6 6.2 8.11 3.41 2.80 8.64 160 188 $4 Insoluble.

Molal Ratio 1:10.. Ex. No Fourth $20 Resin to Et0 Molal Ratio 1:15.- Ex. No

51m s me Resin to R0.

Molal Ratio 1: Ex. No. 1600..."

}3.41 2.80 3.64 3.41 2.80 13.64 80 K Soluble.

[Resin made on pilot plant size batch, approximately 25 pounds para-secondary butylphenol replacing 164 parts by Phenol for resin: Para-secondarybu tylphenol Aldehyde for resin: Furfural :Mix Which is Mix Which Re- Starting Mix fig g gg of Removed for mains as Next Sample tarter Max. Max. Time Pressure, 'lemp era-v hrs Solubility l lbls. Ifibs. Lbs I lb s. gbs. g r b s. gm. Lbs Ibia. 215. Lbs

oeses- 0- es- 0- esvent in Eto vent in Eto vent in Eto vent in First Stage Resin to 16170.... M Molal Ratio 1:1 12. 0 17. 9 12. 0 17.9 3. 5 2. 65 3. 98 0. 77 9. 35 13. 92 2. 73 150 171 Insoluble. Ex. No. 1616.....

Second Stage Slight tend- Resinto EtO-. J \L ency to- Molal Ratio 1:5 9.35 13. 92 2. 73 9. 35 13. 92 13. 23 5.00 7.42 7. 08 4. 35 6.50 6. 100 192 H; ward he Ex. No. 162b coming soluble. Third Stage Resinto EtO 1 Molal Ratio 1:10. 6. 8. 95 6. 25 8.95 17.0 3. 23 4.61 8. 76 3.02 4.34 8. 24 120 188 42 Fairly solu- Ex. No. 163b. ble.

Foarth Stage Resin to Et0 Molal Ratio 1:l5 4.35 6. 50 6. 15 4. 6. 18.40 181 $6 Readily 501- EX. No. 164b uble.

Fifth Stage Resin to EtO- Sample somewhat rubbery and gelat- Molal Ratio 1:20- 3.02 4. 34 8. 24 3. 02 4. 34 16.49 inous but shows limited water sol- 161 44 Ex. No. 165bubillity. I I I [Resin made on pilot plant size batch, approximately 25 pounds, corresponding to 34a of Patent 2,499,370 with 206 Phenol for resini Para-octylpher'zol Aldehyde for resin: Pioz iiorzaldehy de parts by weight of commercial para-octylphenol replacing 164 parts by weight of para tertiary amylphenol but this batch designated as 166a,]

Mix Which is Mix Which Re- Starting Mix figg 0f Removed for mains as Next Sample Starter Max. Max. Time I Pressure, Temp erahrs Solubility lslbls. bs. Lbs 1 .11 3, gm. Lbs 1 .11 5. go's. Lbs lbls. Ifibs. I b5 o eso eso eso esvent in Eto vent in E vent in Eto vent in Eto First Stage Resin to 'Eto Molal Ratio 1 :1..- 13. 3 16. 9 13. 3 16. 9 3. 0. 3. 1 4. 0; 0. 70 10. 2 12. 9 2. 3 100 $5 Insoluble. Ex. No.166b

Second Stage Resin to Et0 Molal Ratio 1:5 10. 2 12. 9 2. 3 10. 2 12. 9 11. 3 6.34 8.03 1. 03 3.86 4. s7 4. 27 100 166 4 B e 00min g Ex. No. 167b soluble.

Third Stage Resin toEtO Molal Ratio 1:113. 6. 46 8. 24 6. 46 8. 24 16. 5 3. 52 4. 49 8. 99 2. 94 3. 75 7. 51 80 177 $4 Fairly solu- Ex. No. 16Sb f ble.

Fourth Stage Resin to EtO Molal Ratio 1:15.. 3. 86 4. 87 4. 27 3.86 4. 87 13. 02 80 204 $4 Readily sol- Ex. N0. 1695"-.- uble.

Fifth Stage Resinto Em... Molal Ratio 1:20.. 2. 94 3. 75 7. 51 2. 94 3. 75 13. 26 100 $4 Soluble. Ex. No. 1706.....

Phenol for resin: Paramowylphenol Aldehyde for resin: Propionaldehyde [Resin made on pilot plant size batch, approximately 25 pounds, corresponding to 8211-01 Patent 2,499,370 but this batch designated as 17112.]

i Mix Which is Mix Which Re- Starting Mix figg ggg of Removed 01' mainsas Next Sample Starter Mam Max.

Pressure, Tempera- 3 Solubility I '1bs.'sq. in. ture, 0. Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. Lbs Sol- Res- Sol- Res- 801- Res- Sol- Resvent in vent in vent in vent in F first Stage Resin to EtO. Molai Ratio 1:1--. 10 9 18.0 10.9 18.0 3.0 2. 65 4.4 0. 75 8. 25 13. 60 2. 25 120 150 M2 Insoluble. Ex. N0. 171b.-.--

Second Stage Resm to EtO M0131 Ratio 1 8. 25 13. 60 2. 25 8. 25 13. O 11. 50 5. 10 8. 35 7. 05 3. 5. 4. 95 174 96 Becoming Ex. N0. 1720. soluble.

Third Stage Resin to EtO.. M01111 Ratio 1:10.. 5 9. 35 5. 65 9. 35 15. 3. 71 6. 14 10. 35 1. 94 3. 21 5. 40 90 182 94a Fairly Ex. No. 1730. soluble.

Fourth Stage Resin to EtQ. M01211 Ratio 1:15.- 3 15 5. 25 4. 45 3. 15 5. 25 13. 45 182 Readily Ex. No. 1745- i soluble.

Fifth Stage Resin to Et0.... MolalRatio 1:20-. 1. 94 3.21 5. 40 1.94 3.21 10.65 150 96 Soluble. Ex. N0. 175b..... v

Phenol forvres'in: Para-tertiary amylphenol Aldehyde for resin: Propionaldehyde [Resin made on pilot plant size batch, approximately 25 pounds, corresponding to 34a of Patent 2,499,370 but this batch designatedas 176a.]

Mix Whichis Mix Which Re- Starting Mix fig figg of Removed for mains as Next Sample f Starter Max Max i Pressure, Temp eragf Solubility 1 Lbs. Lbs; Lbs Lbs. Lbs. Lbs .Lbs. Lbs. Lbs Lbs. Lbs.. Lbs Sol- Res- Sol- Res- Sol- Res- Sol- 1 Res-' vent in vent in vent in vent; m

FirsLStage Resin to Et0.... Molal Ratio 1:1-.- 12 6 16.2 12. 6 16.2. 3. 5 3. 03 3.96 0.85 9. 52 12.24 2.64 Ma Insoluble. Ex. No.176b.... I

Second Stage Resinto EtO I 1 l M01211 Ratio 1:5.-. 9. 52 12. 24 2. 64 9. 52 12. 24 12. 89 5.27 6. 79 7. 14 4. 25 5. 45 5. 75 85 171 96 B e 00min g Ex. No. 17717.. soluble.

Third Stage Resin to EtO.. Molal Ratio 1:10.. 6 5 8.3 6.5 8.3 17.75 3.81 4.87 10.42 2. 69 3.43 7.33 120 183 Pf; Fairly solu- Ex. No. 178b.--.- blo.

Fourth Stage Resin to EtO- I Molal Ratio 1'1 4. 25 5. 45 5. 75 4. 25 5. 45 17.25 85 196 96 Readily sol- Ex. No. 1795..- uble.

Fifth Stage g i Resin to EtO. I Molal Ratio 1:20.. 2 69 3. 43 7.33 2.69 3. 43 14.55 95 $6 Soluble. Ex. No. 180b.- 1- I I suchiasoxalic acid, maleic acid, tartaric acid,

citraconic acid, phthalic acid, adipic acid, suc.- cinic acid, azelaic acid, sebacicacid, adduct acids obtained by reaction betweenmaleic anhydride, citraconic anhydride, and butadiene, diglycollic acid or cyclopentadiene. Oxalic acid is not quitev as satisfactory as some of the other acids due to its ease of decomposition. In light of .raw material costs it is our preference to use phthalic anhydride, maleic anhydride, citraconic anhydride, diglycollic acid, adipic acid, and certain other acids in thesameprice range which are both cheap and heat-resistant. One may also use adduct acidsof the diene or Clocker type having more than carbon atoms, but those reactants having 10' carbon atoms or less are definitely preferred. o V

It is well known that certain monocarboxy organic acids containing 8 carbon atoms or more, and not morethan 32 carbon atoms, are characterizedby the fact that they combine with alkalies to produce soapor soap-like materials. These detergent-forming acids include fatty acids, resin acids, petroleum acids, etc. For the sake of convenience, these acids will be indicated by the formula R.COOH. Certain derivatives of detergent-formingacids react with alkali to produce soap or soap-like materials, and are the obvious equivalent; of the unchanged or. unmodified detergent-forming acids. For instance, instead of fatty .acids, one might employ .the.chlorinated fatty acids. Instead of the resin acids, one, might employ the hydrogenated. resin acids.: Instead of naphthenic.-acids, one might employ brominated naphthenicv acids, etc.

The fatty acids are of thetype commonly re-. ferred to as higher fatty acids; and, of course, this is. also true in regard to derivatives. of thekind indicated, insofar that such derivatives are obtained from higher fatty acids.z The petroleum acids include not only naturally-occurring naphthenic acids but also acidsobtained by the oxidation of wax, paraffin, etc. Such acids may have as many as 32 carbon atoms- For instance, see U. S. Patent No. 2,242,837 dated May 20, v 1941, to Shields.

The monocarboxy detergent-forming esters of the oxyalkylated derivatives herein described are preferably derived from unsaturated fatty acids having 18 carbon atoms. Such unsaturated fatty acids include oleic acid, ricinoleic acid, linoleic acid, linolenic acid, etc. One may employ mixed fatty acids as, for. example, the fatty acids obtained from hydrolysis of cottonseed oil, soyabean oil, etc. It is our ultimate preference that the esters of the kind herein contemplated be derived from unsaturated fatty acids, and more especially, unsaturated fatty acids containing a hydroxyl radical, or unsaturated fatty acids which have been subjected tooxidation. In addition to synthetic carboxy acids obtained by the oxidation or paraflins or the like, there is the somewhat analogous class obtained by treating carbon dioxide or carbon monoxide, in the presence of hydrogen oran olefin, with steam,

having at least one carboxyl group or the equivalent thereof, are suitable as detergent-forming monocarboxy acids; and another analogous class actually suitable is the mixture of carboxylic acids obtained by the alkali treatment of alcohols of high molecular weight formed in the catalytic hydrogenation of carbon monoxide. A

As is well known, one need not use a high molal carboxy acid, such as a fatty acid, for introduc tion of the acyl group or acyloxy group. Any suitable functional equivalent such as the acyl halide, the anhydride, ester, amide, etc., maybe employed. 7

Such polycarboxy reactants and such detergent-forming monocarboxy acids alone or in combination with an appropriate alcohol radical which may be monohydric or polyhydric, have been combined to give suitable reactants for combination with the polyhydroxylated compounds previously described. A particularly suitable type of polycarboxy detergent-forming compound is described in'U. S. Patent No. 2,343,43 dated- March '7, 1944, to Wells and De Groote, and is the identical type herein contemplated, except that in the instant case the detergent-forming acid is limited to those having 32 carbon atoms instead of 38 carbon atoms. Thus, the reactantemployed for combination with the oxyalkylated resin in the words of the aforementioned U. S. Patent No. 2,343,434 is as follows: an ester con-' taining (a) a polyhydric alcohol radical, (b) a polybasic carboxylic acid radical, and (c) an acyloxy radical containing 8 to 38 carbon atoms derived from a detergent-forming monocarboxy acid having 8 to 38 carbon atoms, at least one polyhydric alcohol radical being ester-linked with a group containing said acyloxy radical and the number of said groups ester-linked with at least one polyhydric alcohol radical." It is to' be noted that such reactant is acidic in nature, due to the presence of a free carboxyl radical, and thus'capable of reacting with the hydroxylated oxyalkylated reactant.

In order to avoid repetition, reference is made to said aforementioned U. S. Patent No. 2,343,434, as to the manufacture of the acidic polycarboxy detergent-forming compound, as if the same text appeared herein. For convenience of comparison the same'examples are herein included:

Example 1c mediate is then mixed with 312 pounds of castor oil and the mixture is heated to from 150 to 250 C. for approximately 10 to 30 minutes, after which it is permitted to cool and is diluted with from10% to 50% of denatured alcohol.

In the above reaction the phthalic anhydride, two moles, is united with glycerol, one mole, so as to give a product which corresponds in chemical constants to glycerol diacid phthalate. This product is then reacted with castor oil, mole for mole, so that one mole of water is eliminated and the final product represents approximately one free carboxyl per unit, or approximately one car or' by causing a halogenated hydrocarbon to react with potassium.

39" box-yl, based on a molecular weight oriaoo or acidvalue is. V

' Example 20- Maleic'anhydride is substituted for phthalic anhydride in Example 1c, preceding.

-5 1 Emampledc Adiplc acid is substituted for phtlialic anhydride in Example 10, preceding.

' Ercample alc Succinic acidor anhydride is substituted for pnthalie anhydrideinnxample 1c, preceding.

" Example 50 One-pOundmole of niannitan mono-ricinoleate is esterifled with three pound moles of phthalic anhydride so as to produce the acid tribasic fractio'nal ester.

- Example 6c 'S'orbitan mono-ricinoleate is substituted .for mannitan ricinoleate in the preceding example.

dibasi'c. acid or anhydride' for each pound mole of the oleate.

The products of the esterification reaction produced. according to Examples 10 to 70, are viscous, yellowish, oily materials resembling somewhat blown castor oil in consistency. They are only 3 slightly soluble in either water or in paraffin base mineral oil (not more than 1 part to 1,000) but go into, solution with lower alcohols (methyl to octyl) to form clear solutions. The solutions may be inade up in equal parts, for example.

It to be'noted that the products so produced or any other typical reactants of the same type, are acidic in nature. In all instances, all the products described inv U. S. Patent No. 2,343,434, have an acid value, for instance, f at least 5 to 10 as a minimum, but with 40to 100 as an average value.

Having obtained the oxyalkylated derivativein the acidic polycarboxy reactant above described, it is only necessar 'to mix the two reactants in a predetermined proportion and then cause esterification to take place. Needless to say, esterincation may also'be accompanied by rearrangement or cross-esterification to some degree. Generally speaking, if the two reactants are mixed and heated at a temperature above the boiling point ofwater, and below the pyrolytic point, esterif cation takes place easily and readily. For example, a temperature of 120 to 200 C. may be employed. If need be, a temperature as high as 250 C. can be employed provided it is short of the pyrolytic point. If desired, the reaction can be hastened by the addition of a suitable catalyst, such as paratoluene sulfonic acid. The amount added may be in the neighborhood of one-half of 1%. The reaction can also be hastened by passing dried hydrochloric acid gas through the reaction mixture. The reaction is also hastened by passing any dried inert gas through the mixture, for instance, dried CO2 or dried nitrogen gas.

One of the easiest and simplest ways of ham dling the reaction is to conduct the esterification in the presence of an inert water insoluble solvent, such as benzene, toluene, xylene, cymene,

40- decalin, etc. Our preference is to use xylene or cymene, for the reason that the reflux temperature-is usually more. thansuificient and is high enough toexpedite the elimination of water. The vapors are l ed'to the conventional condenser with the reflux trap-which diverts the water and returns the solvent. These details will. be amplifled somewhat in succeeding examples.

[Example 1d An. 'oxyalkvlated, thermoplastic phenol -aldehyde. resin. such asExample 126b, preceding, was employed asareactant. The hydroxyl value of the oxyalkylated derivative could be calculated without determination, based on the hydroxyl value and weight. otthe phenol-aldehyde resin originally employed, plusthe increase in weight after oxyalkylation. If glycide or methylglycide were employedallowance would have to be made for'tlie'polyhydric character of the oxyalkylating agent. In. any event, if desired, the hydroxyl value of the oxyalkylated derivative could be determined by the Verley-Bolsing method or by any other acceptable. procedure. Similarly, the acid value of the acidicreactant was determined by the usual volumetric titration procedure. Our preferred acidic reactant was the one described under the heading of Example 10. Our preference waste titrate the product to determine its acid. value. Based on the known hydroxyl value of the oxyalkylated derivative and the acid value of thepolycarboxy reactant,- it was our preference to combine such reactants in various proportions so as to add enough of the, polycarboxy reactanttocombine with ,41, /2 or A., or all the theoretical hydroxyl of the oxyalkylated derivative. As an example, the average hydroxyl value for the hyd'roxylated derivative exemplified by Example 126?), was 105. An average acid value for the acidic reactant exemplified by Example 10, was 43.0. Stated another way, this would mean. that the average molecular. equivalent of the 'oxyalkylated derivative was 535, and of the acidic derivative, 1300.0. In other words, ignoring the hydroxyl value of the acidic derivative, if it has any hydroxyl value, means that in following: the proportion above suggested, we prefer to react 1070 pounds of the oxyalkylated derivative with 650, 1300, 1950 and 2600 pounds of the acidic reactant, as previously indicated, which will combinewith /2, 4%, and all the equivalent hydroxyl, respectively.

The esterification was conducted inany conventional; manner, such as merely mixing the reactants alone or inthe presence of a solvent of sufiicientlyhigh boiling point so as to insure reaction. The solvent used could be xylene, cymene, decali'n, etc. Since an acidic reactant was employedv (one having a free carboxyl radical), water was formed. It was convenient sometimes to use a solvent as described in connection with a conventional water trap which separated the water andremoved it from the reaction zone but returned the. excess of solvent.

Although esterification can be conducted in absence of a solvent, we prefer to: employ a solvent, oncre'ason being that esteri-fic'atio'n is best conducted. in a homogeneous system and thus, it thereis any question ofsolubility between the reactants,'there is apt to be an increase in solubility by addition of a suitably selected solvent. It was not necessary to add all the acid reactant atone time; one could-add /4 or /2 the total amount to be esterified and after such portion of the reactant was. combined, then one could 

1. THE RESULTANT OF THE ESTERIFICATION REACTION INVOLVING ON THE ONE HAND AN ACIDIC ESTER CONTAINING: (A) A POLYHYDRIC ALCOHOL RADICAL HAVING NOT MORE THAN 6 CARBON ATOMS AND COMPOSED OF HYDROGEN, CARBON AND OXYGEN; (B) A POLYBASIC CARBOXYLIC ACID RADICAL HAVING NOT MORE THAN 10 CARBON ATOMS; AND (C) AN ACYLOXY RADICAL CONTAINING 8 TO 32 CARBON ATOMS DERIVED FROM A DETERGENT-FORMING MONOCARBOXY ACID HAVING 8 TO 32 CARBON ATOMS, SAID RADICALS BEING JOINED BY ESTER LINKAGES, AT LEAST ONE POLYHYDRIC ALCOHOL RADICAL BEING ESTER-LINKED WITH A GROUP CONTAINING SAID ACYLOXY RADICAL AND THE NUMBER OF SAID GROUPS ESTER-LINKED WITH AT LEAST ONE POLYHYDRIC ALCOHOL RADICAL BEING LESS THAN THE VALENCY OF SAID POLYHYDRIC ALCOHOL RADICAL, AND ON THE OTHER HAND CERTAIN HYDROPHILE SYNTHETIC PRODUCTS; SAID HYDROPHILE SYNTHETIC PRODUCTS BEING OXYALKYLATION PRODUCTS OF (A) AN ALPHA-BETA ALKYLENE OXIDE HAVING NOT MORE THAN 4 CARBON ATOMS AND SELECTED FROM THE CLASS CONSISTING OF ETHYLENE OXIDE, PROPYLENE OXIDE, BUTYLENE OXIDE, GLYCIDE AND METHYLGLYCIDE, AND (B) AN OXYALKYLATIONSUSCEPTIBLE, FUSIBLE, ORGANIC SOLVENT-SOLUBLE, WATER-INSOLUBLE PHENOL-ALDEHYDE RESIN; SAID RESIN BEING DERIVED BY REACTION BETWEEN A DIFUNCTIONAL MONOHYDRIC PHENOL AND AN ALDEHYDE HAVING NOT OVER 8 CARBON ATOMS AND HAVING ONE FUNCTIONAL GROUP REACTIVE TOWARD SAID PHENOL; SAID RESIN BEING FORMED IN THE SUBSTANTIAL ABSENCE OF PHENOLS OF FUNCTIONALITY GREATER THAN TWO; SAID PHENOL BEING OF THE FORMULA 